Battery Module Busbar Assembly for Compact Welding and Gas Venting
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Solution Overview
Problem
The existing battery modules face issues with increased busbar size due to welding of electrode leads and sensing terminals, leading to inefficient space utilization, hindered gas discharge during thermal runaway, reduced welding efficiency, and potential obstruction to high-temperature gas venting.
Innovation Solution
A battery module design featuring a busbar assembly with an insulating support plate and through-holes for electrode leads, allowing overlapping connection and separate welding of electrode leads and sensing terminals, reducing busbar size and improving welding efficiency while enabling smooth gas venting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the busbar size is increased to accommodate both electrode lead welding and sensing terminal welding, then the electrical connection capability is improved, but the space utilization inside the battery module deteriorates
Solution Approach 1:
The patent divides the busbar into multiple sections with different functions: a first busbar portion for welding electrode leads and a second busbar portion for welding sensing terminals. This segmentation allows each portion to be optimized independently, reducing the overall busbar size while maintaining both electrical connection capabilities.
Solution Approach 2:
The patent utilizes the width dimension of the busbar by arranging electrode leads and sensing terminals at different width positions. This dimensional arrangement allows both types of connections to coexist without requiring excessive increase in busbar area, improving space utilization while maintaining adaptability.
2Adaptability or versatility
If the busbar size is increased to weld both electrode leads and sensing terminals, then the electrical connection capability is improved, but the gas discharge capability during thermal runaway deteriorates
Solution Approach 1:
By segmenting the busbar into distinct portions for different functions, the patent creates narrow sections that minimize obstruction to gas flow paths. The segmented structure reduces the overall metal barrier area, allowing high-temperature gas to discharge more smoothly during thermal runaway events.
3Manufacturing precision
If the electrode lead and sensing terminal are welded to the busbar separately, then the electrical connection quality is improved, but the welding efficiency deteriorates
Solution Approach 1:
The patent combines the welding processes by positioning both electrode leads and sensing terminals to be welded to the busbar in close proximity. This allows multiple welding operations to be performed simultaneously or in rapid sequence using a single welding tool, improving welding efficiency while maintaining quality through the separate functional portions of the busbar.
4Adaptability or versatility
If the busbar area is increased to accommodate sensing terminal welding, then the electrical connection capability is improved, but the internal space utilization of the battery module deteriorates
Solution Approach 1:
The patent applies local quality by creating specific welding zones on the busbar with concentrated functionality. The first busbar portion has optimized geometry for electrode lead welding while the second portion is optimized for sensing terminal welding. This localized optimization reduces the total busbar area required while maintaining both electrical connection capabilities.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design enhances space utilization, improves welding quality, and facilitates stable busbar support, ensuring efficient gas discharge during thermal runaway, while reducing manufacturing costs and improving reliability.
Implementation Method 1
The electrode leads may be welded to the busbar... the sensing terminal may be welded to the busbar... the first electrode lead and the second electrode lead are welded to each other... The sensing terminal is welded to at least one of the first electrode lead or the second electrode lead
Data Source
AI summary
A battery module includes a cell assembly including a first battery cell that includes a first electrode lead and a second battery cell that includes a second electrode lead, a busbar assembly including a support plate including a plurality of through-holes, and a busbar electrically connected to the first electrode lead and the second electrode lead, the first electrode lead and the second electrode lead overlapped each other, and a sensing terminal coupled to at least one of the first electrode lead or the second electrode lead. The first electrode lead and the second electrode lead are welded to each other at a first weld region to establish electrical connection. The sensing terminal is welded to at least one of the first electrode lead or the second electrode lead at a second weld region to establish electrical connection.